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Manufacturing Integration @ Avebe with SAP
Real-time visibility
SAP Manufacturing Days ‘s Hertogenbosch, September 11 & 12
© 2013 Quinso. All rights reserved.
www.quinso.com
Introducing …
• Joris Sikking
Managing Consultant | Quinso
• Jos Hensen,
Business Consultant | Avebe
• Kenny van Sleuwen
Solution Architect | Quinso
© 2013 Quinso. All rights reserved.
www.quinso.com
Quinso: High Quality with an Industry Focus …
SAP Consultancy
ERP
SCM
Process
Manufacturing
Trade
Industries
Business Consultancy
Discrete
Manufacturing
SCI
© 2013 Quinso. All rights reserved.
www.quinso.com
Agenda
© 2013 Quinso. All rights reserved.
www.quinso.com
Quinso: Quality in Solutions
• Founded by 5 partners (former KPMG, PWC, SAP, itelligence)
• Highly experienced European Business & SAP Consulting
• Focus on Manufacturing, Trade & Chemical industries
• Special Expertise Partner of SAP (SCM & Shopfloor)
� Supply Chain Management
� Manufacturing (Shopfloor Integration)
• Located in ‘s-Hertogenbosch (NL)
© 2013 Quinso. All rights reserved.
www.quinso.com
Mission & Vision
FLEXIBLE TEAMWORKPRAGMATIC
INVOLVEMENT
LEADERSHIP
FOCUSEXPERIENCE
QUALITY SOLUTIONS
EXPERTISE
ENTREPRENEUR
PARTNER
IMPROVES
COMPETITIVE
PRIMAIRY BUSINESS PROCESSES
SECUNDAIRY BUSINESS PROCESSES
LEADING COMPANY
© 2013 Quinso. All rights reserved.
www.quinso.com
Waarom Quinso? Onze klanten weten waarom …
Trade
Industries
Process
Manufacturing
Discrete
Manufacturing
© 2013 Quinso. All rights reserved.
www.quinso.com
SAP Road Map
© 2013 Quinso. All rights reserved.
www.quinso.com
Manufacturing Integration – Solution Architecture
© 2013 Quinso. All rights reserved.
www.quinso.com
ISA 95 model
• Logistics
• Product Development
• Sales and Marketing
• Etc.
• Maintenance
• Production
• Quality
• Inventory
Layer 4 Business Operations
Layer 3 Manufacturing Operations
Layer 2, 1, 0 Control
• Discrete
• Batch
• Continuous
© 2013 Quinso. All rights reserved.
www.quinso.com
Avebe U.A.
• Since 1919
• Cooperative – Members are shareholders
• Largest potato starch and -derivatives producer in the world - chemical processing
• Annual turnover: 600 million Euro
• Production volume of 600,000 tons (= 30,000 trucks / containers)
Patato Starch an Derivatives
• Total used area: 60,000 acres
• 1350 employees
© 2013 Quinso. All rights reserved.
www.quinso.com
AVEBE Production Plants
Foxhol Ter ApelkanaalGasseltenijveen
Lüchow Dalmin Malmö
© 2013 Quinso. All rights reserved.
www.quinso.com
Background
• Construction of a new factory
• Increase Production
• High and consistent product quality
• "Template": simple rollout to other plants
Less dependent on the individual operator
Automatic dosing
Highly controlled reaction process
Full recipe managed
Automatic registration
Real-time information to the operator
© 2013 Quinso. All rights reserved.
www.quinso.com
Production Integration
Forecast and customer order
Material Requirements
Purchase
Inventory Management
Production Planning
Costing Calculations
Settlement
- Material
- Hours
Replenishment
Inventory Man. Final Product
Inspection and release
Certificates of Analysis (CoA)
Transport
Start of Process Orders
Production Recipe
Equipment allocation
Status of process
Registration of dosing
Sampling and analysis
Process adjustments
Standstill Registration
Batch Reports
Production reports
Tracking & Tracing
Continuous Improvements
Process
Orders
Material Cons.
Hours
Q-dataOrder
status
Replenishment
© 2013 Quinso. All rights reserved.
www.quinso.com
Manufacturing Integration
© 2013 Quinso. All rights reserved.
www.quinso.com
Manufacturing Integration
PCO
Idoc
LOIPRO
PCO
Created
PCO Print
LabelsPCO
CLOSE
tRFC
Z_PCO_PU
LL_LOIPRO
Recipe
Receipt
Info Req.
Rec.
Download
LOIPRO
mapping
SAP Integration Layer
Confirm
PCO
receipt
MCRT
ZPI_HDU
S
US:
MCRT
Product
Pallet
Receipt
By-
Product
PCO
SS: OPEN
US: INIT
PCOSS:
US: INIT
SS: REL/CRCR
US: INIT
PCO
SS: PDLV
US: MSTR
PCO
US: MSTR
SS: PCNF
US: MSTR
PCO
SS: REL
US: MSTR
PCO
SS: REL
US: MCRT
ZPI_HDU
S
US: MSTR
ZPI_PHST
Start date
Batch
ZPI_BYP
R
Quantity,
Batch Batch
ZPI_PRO
D
Quantity,
Batch
ZPI_HDU
S
US: MCLS
PCO
SS:
US: MCLS
SS: PCNF/PDLVUS: MCLS
PCO
SS: PCNF
US: MSTR
ZPI_PHST
Final
Conf.
PCO
SS: CNF
US: MCLS
1
2
3
4
5
6
7 9
1
0
1
3
1
5
2
1
2
4
2
9
3
1
3
0
2
8
2
3
2
0
1
4
1
2
ECC
ZPI_PHST
Quantity
2
6
2
5
PCO
Goods Rec.
By-Prod.
PCO
START
Prod.date
ZPI_BTC
R
Batch nr.
Prod.date
BATCH
Creation
1
8
1
7
82
7
1
9
1
6
1
1
ZPI_FIDE
Final
Delivery
PCO
SS: DLV
US: MCLS
PCO
SS: TECO
US: MCNF
3
3
36
3
2
. Finish
ZPI_CRS
T
Contr.Rec
. Finish
PCO
SS: CRFI
US: MCLS
3
5
3
4
Pallet
Receipt
2
2
© 2013 Quinso. All rights reserved.
www.quinso.com
Template
Chemicals Processing Packaging
Template:
Functional modules for specific processes
• In SAP and in MES
• With its interfaces
Based on Best Practice business processes
© 2013 Quinso. All rights reserved.
www.quinso.com
Benefits for Avebe
Manufacturing Integration
• Significant reduction of administrative tasks by operator
� Fewer input errors and therefore less corrective actions
• Each pallet is directly known in SAP with a unique SSCC code
� Real-time visibility in SAP of the production progress
� (Quality) status per pallet and not per batch
� Prerequisite for introducing new logistics concept
• Basis for "Intelligence" (reports, dashboards, analysis)
SAP
• Using the SAP interface (middleware) tools accelerates the integration
Template
• Lower investment for future implementations, lower overall TCO
© 2013 Quinso. All rights reserved.
www.quinso.com
Benefits for Avebe
Quinso
• Familiar with production processes
• Experience with integration and middleware like PI and MII
• Knowledge of the business processes and design of SAP
• Practical approach
© 2013 Quinso. All rights reserved.
www.quinso.com
Agenda
© 2013 Quinso. All rights reserved.
www.quinso.com
You want to ….
… ensure the most predictable and fastest
time to business value Software
… deliver the integration the business
demands to start and grow without
compromises
… choose from a modular ready to use
portfolio of solution, deployment and
pricing options
© 2013 Quinso. All rights reserved.
www.quinso.com
SAP & Quinso offer Rapid Deployment solutions
to meet specific business needs…
• Software Quickly address the most urgent business processes
• Content SAP best practices, templates and tools make solution adoption easier
• Enablement Guides and educational material speed end user adoption
• Service Fixed scope and price provides maximum predictability and lowers risk
© 2013 Quinso. All rights reserved.
www.quinso.com
… which allow predictability, out-of-the-box integration and adoption choices as
business demands
Predictability
• Fast value in days/weeks
• Fixed cost and fixed best practice scope
Integration
• Integrated start and growth options
• Immediate and future IT and business
processes landscape integrity
Choice
• Modular packages to meet specific business
needs and allow individual adoption paths
• Flexible licensing and deployment options
© 2013 Quinso. All rights reserved.
www.quinso.com
Showtime!
© 2013 Quinso. All rights reserved.
www.quinso.com
SAP Rapid Deployment solutionsDelivering predictable value for your business
Select
What you see, is what you get… at a fixed price and time…
with flexibility to adapt and innovate!
DeployBuy
Run
© 2013 Quinso. All rights reserved.
www.quinso.com
How SAP MII helps you address current manufacturing
challenges…
Performance
� Improve manufacturing processes and customer satisfaction - leverage new revenue opportunities
� Minimize inventory, rework, overtime, and expediting costs – consistently meet budgets
� Improve employee productivity, morale and quality of work life
Responsiveness
Visibility
� Near-time visibility into customer orders across multiple plants – from scheduling to dispatching
� Proactively detect machine, material, labor, and quality issues before customers do
� Evaluate real-time KPIs* and actual production costs and variances against targets
� Respond rapidly and cost-effectively to manufacturing exceptions
� Monitor, measure, analyze and control cost and target variances
� Balance manufacturing priorities against changing demand conditions-align with business objectives
© 2013 Quinso. All rights reserved.
www.quinso.com
iPad: Production Supervisor Cockpit
© 2013 Quinso. All rights reserved.
www.quinso.com
iPad: Production Supervisor Cockpit
© 2013 Quinso. All rights reserved.
www.quinso.com
Key takeaways
• Why?
� Real-time visibility
� Responsiveness, anticipate on changing circumstances
� Maximum Efficiency
� Manufacturing Excellence
• What did we see?
1. Customer Case Avebe
2. Rapid Deployment Solution
• The story continues …
� … at the Quinso stand
© 2013 Quinso. All rights reserved.
www.quinso.com
Agenda
© 2013 Quinso. All rights reserved.
www.quinso.com
Questions?
© 2013 Quinso. All rights reserved.
www.quinso.com
Questions?
Website: www.quinso.com
Linkedin: www.linkedin.com/company/Quinso
Twitter: twitter.com/Quinso_NL
Quinso | Europalaan 8, 5232 BC 's-Hertogenbosch, The Netherlands
T +31 (0)73 68 68 775 | KvK 50340921 | [email protected]